Natural nonwoven materials

Abstract

There is described a nonwoven material comprising a multilayered stack, the multilayered stack comprising discrete interconnected layers, each of the layers, which may be the same or different, comprising a composite fibre of from about 80 to 100% w/w leaf or stem fibre and from about 1 to 20% w/w of a polymer, wherein the polymer is fusible at a temperature of about 180° C. or less. There is also described a novel method of enzyme degumming leaf and/or stem fibres.

1 .- 38 . (canceled) 
     
     
         39 . A method of processing leaf or stem fibres to form a stack composed of a plurality of layers of said leaf or stem fibres, which comprises optionally degumming the leaf or stem fibres. 
     
     
         40 . A method according to  claim 39  which comprises making a nonwoven material comprising a multilayered stack, the multilayered stack comprising discrete interconnected layers, each of the layers, which may be the same or different, comprising a composite fibre of from about 80 to 100% w/w leaf or stem fibre and from about 0 to 20% w/w of a polymer, wherein the polymer is fusible at a temperature of about 120° C. or less, the process comprising:
 a) forming a stack composed of a plurality of layers of leaf or stem fibres, the fibres of each of the plurality of layers being interconnected with the fibres of an adjacent layer; 
 b) interconnecting the plurality of layers together, to form a nonwoven multilayered mat; 
 c) applying a fusible material to the mat. 
 
     
     
         41 . A method according to  claim 39  wherein the leaf or stem fibres are substantially or wholly pineapple leaf fibre. 
     
     
         42 . A method according to  claim 40  wherein the method of interconnection comprises air laying. 
     
     
         43 . A method according to  claim 40  wherein the hydrophilic curable material comprises one or more acrylic resins. 
     
     
         44 . A method according to  claim 39  of which includes degumming the leaf or stem fibre. 
     
     
         45 . A method of making a cured material nonwoven material comprising a multilayered stack, the multilayered stack comprising discrete interconnected layers, each of the layers, which may be the same or different, comprising a composite fibre of from about 80 to 100% w/w leaf or stem fibre and from about 0 to 20% w/w of a polymer, wherein the polymer is fusible at a temperature of about 120° C. or less, the process comprising:
 a) forming a stack composed of a plurality of layers of leaf or stem fibres, the fibres of each of the plurality of layers being interconnected with the fibres of an adjacent layer; 
 b) interconnecting the plurality of layers together, to form a nonwoven multilayered mat; 
 c) applying a fusible material to the mat; 
 d) optionally pressing and fusing, e.g. thermally, the fusible material to form a composite with the leaf or stem fibres; 
 e) applying an optionally pigmented flexible hydrophilic curable material; 
 f) curing the curable material; and 
 e) optionally tumbling the composite cured material. 
 
     
     
         46 . A method according to  claim 45  wherein the cured material is an artificial leather. 
     
     
         47 . A method according to  claim 45  wherein the step of thermally fusing the layers comprising the flexible hydrophilic thermally fusible material is carried out simultaneously, sequentially or separately to the step of pressing the mat. 
     
     
         48 . A method according to  claim 45  wherein the leaf or stem fibres are substantially or wholly pineapple leaf fibre. 
     
     
         49 . A method according to  claim 45  wherein the method of interconnection comprises air laying. 
     
     
         50 . A method according to  claim 45  wherein the hydrophilic curable material comprises one or more acrylic resins. 
     
     
         51 . A method of making a material having the appearance of leather, the process comprising:
 a) forming a stack composed of multiple layers of leaf or stem fibres, especially pineapple leaf fibres, the fibres of each layer being air laid with each other with respect to the fibres of the neighbouring layer or layers;   b) joining the layers together, e.g. by needle punching, to form an interconnected nonwoven mat;   c) applying a flexible hydrophilic resin, e.g. an acrylic resin, to the surface of the mat, and pressing and curing the resin at a temperature above the fusing temperature of the fusing fibre;   d) applying on one or more steps a flexible hydrophilic resin, e.g. an acrylic resin, containing a pigment to the surface of the mat, and curing the resin to produce a web; and   e) tumbling the web.   
     
     
         52 . A method according to  claim 51  wherein the leaf or stem fibres comprise the leaves of one or more plants of the Bromeliaceae family. 
     
     
         53 . A method according to  claim 51  wherein the leaf or stem fibres are substantially or wholly pineapple leaf fibre. 
     
     
         54 . A method according to  claim 51  which further comprises the steps of:
 needle punching the fibres to form a nonwoven mat. 
 
     
     
         55 . A method according to  claim 51  includes the steps of applying a hydrophilic resin to the web, pressing and curing. 
     
     
         56 . A method according to  claim 51  wherein a resin is applied at a temperature above the fusing temperature of the fusing fibre. 
     
     
         57 . A method according to  claim 51  includes the steps of applying a leather finishing composition to the mat, and tumbling the web. 
     
     
         58 . A method according to  claim 51  wherein the multiple layers of leaf or stem fibres are composed of a mixture of 80-95wt % leaf or stem fibres and 5-20wt % of a polymer that is fusible at a temperature below 120° C. 
     
     
         59 . A method according to  claim 51  wherein the process includes a step comprising: pressing the stack at a temperature at which the polymer fuses. 
     
     
         60 . A method according to  claim 51  of which includes degumming the leaf or stem fibre.